Silver coated nylon fibers and associated methods of manufacture and use

Abstract

Silver coated nylon woven and non-woven fibers are disclosed that can be used to make fabrics, bags, and pads that are silver coated on one side of the fabric, bag, and/or pad. Silver coated nylon fabrics, bags, and pads provide an antimicrobial surface which remains on the surface and retains its antimicrobial characteristic until destroyed. The silver coating can be used as a way to eliminate, reduce and/or ameliorate odors emanating from the bacteria. The methods of adherence of the silver to the nylon may be performed in a number of ways. The pads may be further associated with protective gear that can be used by professions and athletes that use protective gear.

Description

[0001]The present application claims priority under 35 USC §120 as a continuation in part application of U.S. application Ser. No. 12 / 317,732 filed Dec. 29, 2008, the entire contents of which are herein incorporated by reference in its entirety.FIELD OF THE INVENTION[0002]The invention relates to methods of making and utilizing silver coated nylon fabrics. The invention also relates to overcoming the existing technological barriers for dyeing silver coated nylon fabrics. Prior silver coated nylon fabrics were 100% nylon and the surface was 100% silver coated following the fabric manufacturing process. Such fabrics are not suitable for end uses because of the critical obstacle of consumer desire for color in apparel. The fabrics currently available do not allow the application of color because 100% silver coated nylon fabric cannot hold dyes. Conversely, this invention involves creating silver coated nylon fabrics by incorporating the silver during or after the fabric making process,...

AI Technical Summary

Benefits of technology

[0031]The middle layer can be a polyurethane film or another suitable film such as polyethylene, polypropylene, polyetherimide, polyetherimide esters, acrylic resins, synthetic rubbers, ethylene vinyl acetate copolymer resins or other copolymer resins that provides the waterproofing, and additional strength to the bag. In one embodiment, the middle layer is polyurethane. The first layer of the fabric, in one embodiment, is a non-woven 70 / 30 poly / silver coated nylon blend. Alternatively, the first layer is a 50% polyester and 50% nylon blend, a 30 / 70 poly / silver coated nylon blend, or a blend between 95 / 5 and 5 / 95 poly / silver coated nylon blend. The nylon fibers are electrolessly coated with silver, and by weight, can have a silver coating of as low as 5% and as high as 30%. In another embodiment, the first layer can be comprised of 100% silver coated nylon fabric, knitted, woven or non-woven. The electrolessly coated nylon fibers are coated by silver, and by weight, can have a silver coating as low as 5% and as high as 30% or alternatively, as low as 2% and as high as 30% by weight. In another embodiment, the present invention relates to a foam pad that comprises a three layer laminate having a polyester / silver coated nylon non-woven fabric layer, that is laminated to an open cell foam layer (as the middle layer) and a PSA (pressure sensitive peelable adhesive layer) on the other side. In one embodiment, polyester / silver coated nylon non-woven fabric layer is a non-woven 70 / 30 poly / silver coated nylon blend. Alternatively, the polyester / silver coated nylon non-woven fabric layer is a 50% polyester and 50% nylon blend, a 30 / 70 poly / silver coated nylon blend, or a blend between 95 / 5 and 595 silver coated nylon fibers. In another embodiment, the Polyester / Silver Coated Nylon Non-Woven fabric layer could be a knitted or woven fabric. In addition, the knitted, woven or non-woven silver coated nylon fabric could comprise of 100% silver coated nylon fibers or yarns. The silver coating could be, by weight, as low as 5% of the nylon fibers and up to 30% of the nylon fibers or alternatively, as low as 2% and as high as 30% by weight. The adhesive may be a reactive or non-reactive adhesive. In an embodiment, the adhesive may be either a solvent based adhesive or polymer dispersion adhesives (an emulsion adhesive) or a combination of the two. The adhesive may be one or more of various types of glue, such as a pressure sensitive adhesive or a heat sensitive adhesive. Alternatively and or additionally, the adhesive may be an animal protein based adhesive such as albumin glues, casein glues, or meat glues. The adhesive may be a plant based glue such as Canada balsam, Coccoina, gum Arabic, a latex based glue, a starch based glue, a methyl cellulose based glue, a mucilage based glue, a resorcinol resin, or a urea-formaldehyde based glue. Alternatively and / or additionally, the adhesive may be a polystyrene cement / butanone, or a dichloromethane based adhesive. Alternatively and / or additionally, the adhesive may be an acrylonitrile based glue, cyanoacrylate based glue, an acrylic based monomer glue, or a resorcinol based glue. Alternatively and / or additionally, the adhesive may be an epoxy resin, an epoxy putty, an ethylene-vinyl acetate based glue (hot melt glue), a phenol formaldehyde based glue, a polyamide based glue, a polyester resin based adhesive, a polypropylene based glue, a polysulfide based glue, a polyurethane based glue, a polyvinyl acetate based glue, a polyvinyl alcohol based glue, polyvinyl chloride based glue, a polyvinylpyrrolidone based glue, a rubber cement, a silicone based glue, an acrylic copolymer, a styrene acrylic copolymer based glue, a styrene-butadiene-styrene, a styrene-isoprene-styrene, and / or a silicone polymer based glue. In one embodiment, the foam pad is part of protective gear for work related purposes, such as any profession that uses protective gear including but not limited to construction workers, carpenters, masons, tile layers, factory workers, welders, policemen, firemen, smelt workers, utility workers, and other professions that use protective gear. In another embodiment, the foam pad is part of protective gear for sports related activities. For example, the adhesive, side of the pad may be attached to the protective gear. For example, the protective gear may be used for padding used in any sport including but not limited to football, soccer, lacrosse, hockey, field hockey, fencing, epee, jai alai, sailing, spelunking, diving, scubaing, rowing, basketball, baseball, tennis, cycling, boxing, mixed martial arts, judo, taekwondo, wrestling, dancing, golf, auto racing, volleyball, weightlifting, track and field events, cricket, rugby, horse racing, equestrian events, swimming, polo, water polo, figure skating, speed skating, skiing, ski-jumping, luge, bobsled, skeleton, snowboarding, Olympic game sports, X-games sports, and others. In one embodiment, the foam pad is attached to the protective gear so that the silver side of the foam pad is adjacent to the athlete's skin. Thus, the odor emanating from the bacteria that build up due to sweat is eliminated, reduced and / or ameliorated. In an embodiment, the foam pad is part of or can be adhered to (by the adhesive) to any one or more of a shin pad, a helmet, a shoulder pad, a knee pad, a glove, a chest pad, a sock, a shoe, an arm pad, a leg pad, a hip pad, a back pad, a stomach pad, an elbow pad, an ankle pad, or another pad. In a variation, the foam pad is part of a shin pad, a helmet, a shoulder pad, a knee pad, a glove, a chest pad, a sock, a shoe, a hip pad, an elbow pad, or an ankle pad. In an embodiment, it is part of a shin pad. In another embodiment, the present invention relates to a pad that comprises a two layer laminate comprising a polyester / silver coated nylon non-woven fabric that is laminated to a PSA (pressure sensitive peelable adhesive layer) on one side and a poly / silver nylon on the other side. Similar to the three layer pad, the pad may be associated with protective gear for work related or sports related activities. For example, the adhesive side of the pad may be attached to the protective gear. The adhesive side may use any of the adhesives mentioned above that may be used in connection with the three layered pad and the silver side may be any of the silver ratios that are discussed above in connection with the three layered pad. The silver side is adjacent to the skin of the worker and / or athlete, which when said individual sweats, the odor emanating from the bacteria is eliminated, reduced and / or ameliorated.

[0032]In an embodiment, the pad may be part of a mat that can be used for any of a variety of purposes. In one variation, the mat may be designed for young children in school that take naps during their time in school. Alternatively and / or additionally, the pad may be part of a yoga mat or dance mat or a workout mat so that the silver is adjacent to the person working out (or performing yoga or dance). The silver serves the function of eliminating, reducing and / or ameliorating any odor that emanates from the sweat of the person working out and / or performing dance and / or yoga. In an embodiment, the silver may be on the other side (facing the floor) thus killing any bacteria on the floor, which in turn eliminates, ameliorates or reduces the odor emanating from any bacteria. In a variation, the mat that contains silver coated nylon non-woven fabric on one side can be rolled up for easy transportation. In an embodiment, the mat may have foam associated with it for the comfort of the person working out (or for the practitioner of yoga and / or dance). The mat may also have a surface opposite the silver side that has some friction associated with it so that it does not slide on the floor or surface upon which the mat rests when the person sleeps, works out (or performs yoga and / or dance).

[0033]In an embodiment, the pad of the present invention can be used as an exercise and / or wrestling mat. In one embodiment, the silver may be present on the other side of where the exerciser and / or wrestler exercises and / or wrestles. When the silver is present on the bottom of the mat, the silver kills any bacteria that may be present on the floor, thus eliminating, ameliorating or reducing any odor emanating from any bacteria that may be on the floor. In a variation, the pad may be part of a wrestling or exercise mat wherein the mat can be rolled up. The silver on one side (or alternatively on both sides) eliminates, ameliorates or reduces the odor emanating from any bacteria when rolled up, greatly reducing any odor.

[0034]In an embodiment, the pad may have an adhesive such as Velcro which allows attachment to the top tube or bottom tube of a bicycle (either a road bike or a mountain bike) frame or allows the pad to attach to itself so that a rider on a trainer (or on rollers) may ride in a stationary fashion so that sweat does not drop on the top tube or bottom tube of the bicycle frame. In a variation, the silver is deposed so that it is facing outwards from the bicycle top tube or bottom tube of the frame so that any sweat that hits the pad does not hit the frame thereby eliminating, reducing and / or ameliorating any odor that emanates from the sweat while at the same time protecting the frame from sweat.

[0035]In an embodiment, the pads (and other products) are made to absorb a sufficient amount of moisture. In an embodiment, the pads (and other products) have the ability to absorb up to 80% by weight of water within 30 minutes. Alternatively, the pads (and other products) can absorb between 70-105% by weight of water within 30 minutes. In a variation, the pads (and other products) have the ability to absorb up to 50% by weight of water within 30 minutes. In an embodiment, the silver coated non-woven fabric with a foam backing has the ability to absorb up to 300% by weight of water within 30 minutes. The ability of the pads (and other products) to absorb moisture allow sweat to be removed from adjacent the skin (via wicking or some other process) while the silver is still present allowing the pads (and other products) to kill any bacteria that may be present in the sweat, thus eliminating, ameliorating or reducing any odor emanating from any bacteria.

[0036]In all embodiments of the silver coated nylon fiber pads, they are not intended for use in wound care as it is expected that the product the pad will be applied to will be reused over and over again after each activity. In normal situations, the odor, on sports or work gear, caused by bacteria, is produced after the wearer has stopped wearing the equipment, and while the gear is still wet. The purpose of applying the pad to sports / work gear and equipment, is so that while the pad is not being worn, which is the majority of the time, the silver has time to kill the odor causing bacteria, thus the next time the activity takes place, there is no odor on the equipment and it can be used again as normal.

Problems solved by technology

Silver has also been applied topically to fabrics as an antimicrobial agent but the process has lacked efficacy because the % of silver is generally less than 3%, the fabrics are not conductive because there is not a 100% coating of silver.

These fabrics can be dyed but do not have the thermal conductivity or electrical conductivity of 100% silver plated fabrics.

These fibers are dyeable but are not thermally or electrically conductive and are not as effective in killing bacteria due to the low concentration of silver.

Although these fabrics can be dyed, they still suffer from drawbacks including the inability to conduct electricity, and ineffective antimicrobial activity.

Previously, attempts to apply these specific micro-biocides on the surfaces of fabrics and yarns have been unsuccessful.

The dyeable fabrics as previously manufactured had a durability issue if treatment was topical and antimicrobial efficacy drawbacks (i.e., the kill rate above 99% / log kill rate ratio is over 2.0) if silver was added to the polymer prior to spinning.

Thus, using the old methodology, the efficacy is much less than the electrolessly deposited silver coated nylon.

Although these silver-based agents provide relatively good, semi-durable, antimicrobial properties, they tend not to produce the desired long-lasting, wash-resistant, silver-based antimicrobial textile.

Moreover, these fabrics tend to lack the thermal and electrical conductive properties of electrolessly silver plated fabrics.